ENERGY STARENERGY STARfor Manufactured Homesfor Manufactured Homes

Quality Assurance PerspectiveQuality Assurance Perspective

Program overviewProgram overview

• ~120 plants nationwide qualified to produce ENERGY STAR manufactured homes

• About 30 plants (excluding the NW) are actively producing ENERGY STAR-qualified homes

Three components to the programThree components to the program

• Plant certification – one time process• Production and in-plant inspection of

homes• Field inspection and tests

Certification Step 1:Certification Step 1:Retail a Retail a Certifier Certifier

• Retain an ENERGY STAR manufactured home plant certifier

• Independent, third-party with expertise in factory building techniques and energy efficiency In-plant inspection

Certification Step 2:Certification Step 2:Design HomesDesign Homes

• Design homes to meet ENERGY STAR requirements

• Prescriptive packages or computer analysis

Plan review

Certification Step 3:Certification Step 3:Incorporate design into QC processIncorporate design into QC process

• ENERGY STAR features incorporated into:–– Design Approval Design Approval

Primary Inspection Primary Inspection Agency (DAPIA)Agency (DAPIA)--approved packagesapproved packages

–– Plant Quality Control Plant Quality Control ManualManual

–– ManufacturerManufacturer’’s s Installation ManualInstallation Manual

Certification Step 4:Certification Step 4:Test Homes in the PlantTest Homes in the Plant

• Manufacture and verify the performance of three consecutive homes

• Test ducts• Certifier verifies that

the ducts do not exceed allowable leakage levels

In-plant inspection

Certification Step 5:Certification Step 5:Develop Site Installation ChecklistDevelop Site Installation Checklist

• The Site Installation Checklist identifies items that are part of the ENERGY STAR design package verified at the time of home installation

• Certifier approves approves checklistchecklist

D.1

SAMPLE ENERGY STAR QUALIFIED MANUFACTUREDHOME SITE INSTALLATION CHECKLIST

A P P E N D I X D

* The retailer and/or homeowner may be contacted as part of the ENERGY STAR for Homes quality assurance program.

Note: This form can be automatically custom-generated for each home by the MHRA ENERGY STAR Information Manager

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Instructions for manufacturer's field representative:1. Fill in retailer and homeowner contact information. 2. Verify that all ENERGY STAR CONSTRUCTION REQUIREMENTS listed below have been successfully completed. 3. Confirm that the EPA ENERGY STAR and MHRA Quality Assured labels are affixed to the home.4. When all ENERGY STAR construction requirements have been successfully completed:

• Sign and date this form.• Sign and date the MHRA Quality AssuredTM label (near the HUD data plate or the main electrical panel). • Promptly return this completed form to the manufacturer.

If there are any discrepancies, contact the manufacturer immediately.

RETAILER*

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HOMEOWNER*

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ENERGY STAR CONSTRUCTION REQUIREMENTS

A. Marriage Line SealThe marriage line areas must be filled with a continuous non-porous insulating gasket creating a permanent air barrier at joints in the ceiling, walls andfloor. Acceptable gaskets can be one or two-part systems, including proprietary gaskets, foams, insulation wrapped in poly, and insulation covered by butylor other long-life tape on one side. In addition, there must be no visible signs of gaps or tears.

B. Tears in Bottom Board Material RepairedAll tears in the bottom board material must be covered and sealed with a durable, permanent patch to prevent air leakage. (Foam sealant can be used on lagbolt and other small holes.)

C. Exterior (Including Crossover) Duct InstallationFor multi-section homes, the exterior ducts must be sealed with a permanent connection per the Manufacturer's Installation Manual. Identify that the following items are completed:

All exterior ducts have been installed and wrapped with insulation.

Crossover collar is secured to the trunk with at least three screws and cannot rotate or move.

All exterior duct insulation is a minimum of R-_______.

Nylon or metal straps and saddles are used to support the exterior duct; duct does not touch the ground.

Three or more screws are placed below the straps through the flexible duct and into the crossover collar.

Exterior duct insulation is pushed into the floor cavity and sealed with tape or foam sealant at all bottom board penetrations.

D. Field Installed Heat Pump

Heating equipment efficiency meets or exceeds the following specification: HSPF-_______.

E. For Homes Installed Over Basements (One of the following must be checked)This home has an UNHEATED BASEMENT. All interior stairwells from the heated space into the basement are constructed in the same manner as an exterior wall with full insulation and a weather-stripped, insulated exterior door.

This home has a HEATED BASEMENT. The basement wall insulation level is a minimum of: R-_______.

Signature (Manufacturer's Representative) Print Name Date

Fax this completed form to ______________________________________ or mail to the home manufacturer at the address above.Fax Number

HOME MANUFACTURER

Company Contact Telephone

Name Telephone

Company Contact Home serial number

Address City State Telephone

Address City State

Address City State County

A copy of the Sample ENERGY STAR Manufactured Home Site Installation Checklist is available on the web at: http://www.mhrahome.org. This is a modelchecklist. Manufacturers may have their own.

Certification Step 6:Certification Step 6:Field TestsField Tests

• Install three ENERGY STAR qualified homes in the field

• Test for shell and duct leakage

• Certifier verifies that maximum allowable levels are not exceeded

Certification Step 7:Certification Step 7:Incorporate into Routine Operations Incorporate into Routine Operations

• Transfer lessons learned from the certification process into routine production of ENERGY STAR qualified homes

Ceiling drywall is foamed to roof trusses

Certification Step 8:Certification Step 8:Submit Documentation Submit Documentation

• Certifier submits to MHRA the plant certification form

• Plant submits to EPA the ENERGY STAR partnership agreement

Producing ENERGY STAR Producing ENERGY STAR Qualified HomesQualified Homes

Producing Step 1:Producing Step 1:Manufacture and Inspect HomesManufacture and Inspect Homes

• Manufacture homes in accordance with the approved designs

• Every home is inspected on the production line

• Homes display the ENERGY STAR label and Quality Assured label

EPA and MHRA labels

Producing Step 2:Producing Step 2:Install and Inspect Homes in the Field Install and Inspect Homes in the Field

• Plant representative uses Site Installation Checklist to monitor set-up

• Non-compliance items fixed on site

• Site Installation Checklist completed, signed by the plant representative and returned to the plant

Home installation

Maintaining Plant Maintaining Plant CertificationCertification

Maintaining Step 1:Maintaining Step 1:Use the MHRA Information ManagerUse the MHRA Information Manager

• Web-based system used by plants to keep track of and report production of ENERGY STAR qualified homes

MHRA ENERGY STAR Information Manager

Maintaining Step 2:Maintaining Step 2:ConductConduct Field EvaluationsField Evaluations

• Plant must at all times retain an accredited ENERGY STAR Certifier

• Certifier conducts field evaluations on 2 percent of each plant’s ENERGY STAR qualified homes

Field Evaluation: InspectionField Evaluation: Inspection

Verify the following• Documentation, including DAPIA package• Labels• Equipment efficiency• Set-up requirements (crossover duct, bottom

board)• Basement insulation

Field Evaluations: TestingField Evaluations: Testing

• Duct leakage• Shell leakage

Field blower door test

Field duct blaster test

Quality enhancersQuality enhancers

• The manufacturing environment– Leveraging the in place quality control process– Production methods made possible by

building in a plant (e.g., large dry wall sheets foamed to roof framing for air-tight seal)

– Investment by plant in proven techniques (duct blaster testing in plant)

Quality enhancersQuality enhancers

• Features of manufactured homes– Simple construction detailing and design– Universal application of prescriptive features

(factory-installed marriage joint gasket)– simple wall/roof thermal envelope without

many corners and complicated shapes– fully installed homes without complicated

dormers, garage/home interfaces

Rapid Dissemination of Energy Rapid Dissemination of Energy InnovationsInnovations

In-plant duct test

Factory-installed marriage line gasket for through-the-rim crossover

Wide use of mastic for duct sealing

Rapid Dissemination of Energy Rapid Dissemination of Energy InnovationsInnovations

Quality enhancersQuality enhancers

• Continuous improvement– Less than 20 Certifiers nationwide, some

working in association with local HERs raters (some are also HERs raters)

– Requirement of all Certifiers to attend three meetings per year

– Real time monitoring of every ENERGY STAR manufactured home build assuring timely and effective QC oversight

Training plant personnel on the proper application of mastic

Duct tightness testing in the plant

Culture of Continuous Culture of Continuous ImprovementImprovement

More informationMore information

Making Design Decisions

Selecting the System Type

Making the Connections

Planning the System

MANUFACTURED HOUSINGDUCT SYSTEMS:

GUIDE TO BEST PRACTICES

Excellence in Design,

Manufacturing and Installation Series

Further information:

Manufactured Housing Research Alliance2109 Broadway, Suite 200New York, NY 10025

Contact: Gwynne KochEmail: gkoch@research-alliance.org

Web: www.mhrahome.org